A close-up view of surface-mount components on a circuit board

Smaller Is Sometimes Better: Why Electronic Components Are So Tiny

Perhaps the second most famous law in electronics after Ohm’s law is Moore’s law: the number of transistors that can be made on an integrated circuit doubles every two years or so. Since the physical size of chips remains roughly the same, this implies that the individual transistors become smaller over time. We’ve come to expect new generations of chips with a smaller feature size to come along at a regular pace, but what exactly is the point of making things smaller? And does smaller always mean better?

Smaller Size Means Better Performance

Over the past century, electronic engineering has improved massively. In the 1920s, a state-of-the-art AM radio contained several vacuum tubes, a few enormous inductors, capacitors and resistors, several dozen meters of wire to act as an antenna, and a big bank of batteries to power the whole thing. Today, you can listen to a dozen music streaming services on a device that fits in your pocket and can do a gazillion more things. But miniaturization is not just done for ease of carrying: it is absolutely necessary to achieve the performance we’ve come to expect of our devices today. Continue reading “Smaller Is Sometimes Better: Why Electronic Components Are So Tiny”

Liberating The ESP8266 From Its Development Board

While the ESP32 is clearly a superior piece of hardware, we think you’ll agree that the ESP8266 is just too useful not to have a dozen or so kicking around the parts bin at any given time. Cheap, easy to use, and just enough capabilities to bring your projects into the wonderful world of IoT. But if you really want to get the most out of it, you’ll eventually have to skip the development board and start working with the bare module itself.

It can be a scary transition, but luckily, [Ray] has collected some notes that should prove helpful for anyone looking use modules like the ESP-12F in their own custom PCBs. From different tips on making sure the power-hungry modules get enough juice, to cost cutting measures that help reduce the ancillary parts needed in your circuit design, it’s a worthwhile read for new and experienced ESP8266 wranglers alike.

An auto-reset circuit with the CH340C

For example, [Ray] talks a bit about using the infamous GPIO10 pin. This pin is on the rear of the ESP8266 module, and on many development boards, it isn’t even connected. That’s because its internally hooked up to the ESP8266’s SPI flash chip, and using it can cause problems if you’re not careful. But as explained in the blog post, as long as you make sure the flash mode is set to “dual IO” (DIO), then GPIO10 can be used just like any other free pin.

We also really liked the tip [Ray] shares at the end for making your boards more easily programmable. Sure you can leave an unpopulated header on the board, or fiddle with some pogo pin setup, but his edge connector approach is quite clever. Just slip the programmer on for the initial burn, and then after that you can update over the air.

There’s no denying how easy it is to throw something together with an ESP8266 development board, but we’ve covered so many incredible projects that have made use of the bare module’s diminutive dimensions that you’ll ultimately be missing out if you don’t cut out the middle-man.

Dream Bigger, Predict The Future

I’d love to tell you that I’m never wrong, but I’ve been wrong a lot. Remember the Arduino? When it was brand new, I thought it was some silly collection of libraries and a drop-down menu for people who are too lazy to just type out their own #include statements. Needless to say, it launched about a million hacks and brought microcontroller programming into the mainstream. Oops.

Similarly, about fifteen years ago, I saw an educational project out of MIT’s Media Lab. It consisted of a bunch of blocks that had LCD screens on them and would interact with each other when put together. The real hook, though, was that each block had an accelerometer inside, so you could “pour water” out of one block into another, for instance.

At that time, accelerometers were expensive, even in quantities. Even one of these cubes must have cost $100 at the time, much less a whole set. Accelerometers were so expensive that I wouldn’t have thought about incorporating one into a project, much less a dozen, so I ignored them for hacker purposes. Then came the cellphone and economies of scale. Today, even in chip shortage times, they’re readily available for around $2 each, making them useful for exactly this kind of “frivolous” use.

From the Arduino experience, I learned to never underestimate the impact of what seem to me to be “small” conveniences. (And maybe more so, the value of the tremendous common effort from the community.) From the MIT accelerometer story, the moral is that some parts will get drastically cheaper in the future, so you shouldn’t necessarily exclude the cool new sensor from your design repertoire. After all, ten years ago, nobody would have thought that we’d have laser time-of-flight rangefinders for less than a hamburger.

What new components are fantastically useful, or full of potential, that might be cheap enough in the future to make them also worth looking into? Swing by Hackaday tomorrow morning and join in the conversation!

Is A Diode A Switch?

Many hardware people around these parts will be familiar with devices used as switches, using at least three-terminals to effect this, an input, an output and a gate. Typical devices that spring to mind are bipolar transistors, triacs and and ye olde triode valve. Can you use a diode to switch a signal even if it has only two terminals? Of course you can, and it’s a tried and trusted technique very common in test equipment and circuits that handle RF signals. (Video, embedded below.)

The trick is that diodes block current in one direction but allow it to flow in the other, denoted by the deliberately obvious symbol. So your DC signals can’t swim upstream, but the same isn’t true for AC. Signals can be passed “the wrong way” through a diode by inducing small fluctuations in the current. Put another way, if you bias the diode into conduction, changes in the downstream voltage level result in changes in the current flowing through the diode, and the (smaller) AC signal gets through. But if you take away the bias, by turning off the DC bias voltage source, the diode switches back to non-conducting, blocking the signal. And that makes a diode a DC controlled switch for AC signals.

While [IMSAI Guy] demonstrates this with a signal diode, as he explains, one would typically use a PIN diode, which has an extra intrinsic (undoped) region between the P and the N, allowing the device to fully turn off, reducing leakage significantly.

Of course, we’ve covered diodes many times from different angles, there is always something to learn. Checkout how high voltage diodes are constructed, diodes detecting ionising radiation, and finally this great series about our new favourite two-terminal device.

See, the humble diode can be fun after all!

Continue reading “Is A Diode A Switch?”

Decoding SMD Part Markings

You’ve probably encountered this before — you have a circuit board that is poorly documented, and want to know the part number of a tiny SMD chip. Retro computer enthusiast [JohnK] recently tweeted about one such database that he recently found, entitled The Ultimate SMD Marking Codes Database. This data base is only a couple of years old judging from the Wayback Machine, but seems to be fairly exhaustive and can be found referenced in quite a few electronics forums.

Unlike their larger SMD siblings, these chips in question are so small that there is no room to print the entire part number on the device. Instead, the standard practice is for manufacturers use an abbreviated code of just a few characters. These codes are only unique to each part or package, and aren’t necessarily unique across an entire product line. And just because it is standard practice does not imply the marking codes themselves follow any standard whatsoever. This seemingly hodgepodge system works just fine for the development, procurement and manufacturing phases of a product’s lifecycle. It’s during the repair, refurbishment, or just hacking for fun phases where these codes can leave you scratching your head.

Several sites like the one [JohnK] found have been around for years, and adding yet another database to your toolbox is a good thing. But none of them will ever be exhaustive. There’s a good reason for that — maintaining such a database would be a herculean task. Just finding the part marking information for a known chip can be difficult. Some manufacturers put it clearly in the data sheet, and some refer you to other documentation which may or may not be readily available. And some manufacturers ask you to contact them for this information — presumably because it is dynamic changes from time to time. Continue reading “Decoding SMD Part Markings”

Investigating A Defective USB Power Bank Module

Call us old fashioned, but we feel like when you buy a piece of hardware, the thing should actually function. Now don’t get us wrong, like most of you, we’re willing to put up with the occasional dud so long as the price is right. But when something you just bought is so screwed up internally that there’s no chance it ever could have ever worked in the first place, that’s a very different story.

Unfortunately, that’s exactly what [Majenko] discovered when he tried out one of the USB-C power bank modules he recently ordered. The seemed to charge the battery well enough, but when he plugged a device into the USB output, he got nothing. We don’t mean just a low voltage either, probing with his meter, he became increasingly convinced that the 5 V pin on the module’s IP5306 chip literally wasn’t connected to anything.

So close, yet so far away.

Curious to know what had gone wrong, he removed all the components from the board and started sanding off the solder mask. With the copper exposed, his suspicions were confirmed. While they did route a trace from the chip to the via that would take the 5 V output the other side of the board, it wasn’t actually connected.

This is a pretty blatant bug to get left in the board, but to be fair, something similar has happened at least once or twice to pretty much everyone who’s ever designed their own PCB. Then again, those people didn’t leave said flaw in a commercially released module…

Continue reading “Investigating A Defective USB Power Bank Module”

What Goes Into A High Voltage Diode?

When we use an electronic component, we have some idea of what goes on inside it. We know that inside a transistor there’s a little piece of semiconductor with a junction made from differently doped regions etched into it, and in a capacitor, there will be metalized plates on the surface of some kind of dielectric. Reverse engineering has given us extensive die photography of integrated circuits, but there remain a few component mysteries to be uncovered. One is laid bare by [WizardTim], as he cross-sections a 20KV high-voltage diode.

A conventional low-voltage silicon diode has a forward voltage drop of about 0.7V and a relatively low maximum reverse voltage, for example with the 1N4001 rectifier it’s 50V.  For the higher-spec 1N4007, the reverse voltage rating is 700V. This diode has a 25KV reverse voltage, and a clue to its construction comes in its quoted 45V forward voltage. Sure enough, when mounted in resin and carefully sanded and polished flat it reveals its interior as a stack of diodes in series to increase the reverse voltage at the expense of forward voltage.

Revealing the inner workings of an unusual component is fascinating, and the lapping technique used is definitely worth a look. It’s something we’ve seen before, for example in reducing CPU thickness for increased performance.

Continue reading “What Goes Into A High Voltage Diode?”